US11670505B2 - Semiconductor substrate, semiconductor device, and method for forming semiconductor structure - Google Patents
Semiconductor substrate, semiconductor device, and method for forming semiconductor structure Download PDFInfo
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- US11670505B2 US11670505B2 US17/005,542 US202017005542A US11670505B2 US 11670505 B2 US11670505 B2 US 11670505B2 US 202017005542 A US202017005542 A US 202017005542A US 11670505 B2 US11670505 B2 US 11670505B2
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- H10D30/47—FETs having zero-dimensional [0D], one-dimensional [1D] or two-dimensional [2D] charge carrier gas channels having 2D charge carrier gas channels, e.g. nanoribbon FETs or high electron mobility transistors [HEMT]
- H10D30/471—High electron mobility transistors [HEMT] or high hole mobility transistors [HHMT]
- H10D30/475—High electron mobility transistors [HEMT] or high hole mobility transistors [HHMT] having wider bandgap layer formed on top of lower bandgap active layer, e.g. undoped barrier HEMTs such as i-AlGaN/GaN HEMTs
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- H10D62/85—Semiconductor bodies, or regions thereof, of devices having potential barriers characterised by the materials being Group III-V materials, e.g. GaAs
- H10D62/8503—Nitride Group III-V materials, e.g. AlN or GaN
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- H10D62/82—Heterojunctions
- H10D62/824—Heterojunctions comprising only Group III-V materials heterojunctions, e.g. GaN/AlGaN heterojunctions
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Definitions
- the embodiment of the present disclosure relates to semiconductor techniques, and in particular it relates to a semiconductor structure having a seed layer and methods for forming the same.
- GaN-based semiconductor materials have many excellent material properties, such as high heat resistance, wide band-gaps, and high electron saturation rates. Therefore, GaN-based semiconductor materials are suitable for high-speed and high-temperature operating environments. In recent years, GaN-based semiconductor materials have been widely used in light-emitting diodes (LEDs) and high-frequency elements, such as high electron mobility transistors (HEMTs) having a heterojunction structure.
- LEDs light-emitting diodes
- HEMTs high electron mobility transistors
- the semiconductor substrate includes a ceramic base having a front surface and a back surface, and the front surface is a non-flat surface.
- the semiconductor substrate also includes a seed layer disposed on the front surface of the ceramic base.
- the semiconductor substrate further includes a nucleation layer disposed on the seed layer.
- the semiconductor device includes the above-described semiconductor substrate.
- the semiconductor device also includes a compound semiconductor layer disposed on the nucleation layer.
- the semiconductor device also includes a gate disposed on the compound semiconductor layer.
- the semiconductor device further includes a source and a drain disposed on the semiconductor layer and on opposite sides of the gate.
- Some embodiments of the disclosure provide a method for forming a semiconductor structure.
- the method includes providing a ceramic base having a front surface and a back surface, and the front surface is a non-flat surface.
- the method also includes forming a seed layer on the front surface of the ceramic base.
- the method further includes forming a nucleation layer on the seed layer.
- FIGS. 1 A- 1 E illustrate intermediate stages of forming a semiconductor structure in accordance with some embodiments of the disclosure.
- FIGS. 2 A- 2 F illustrate intermediate stages of forming a semiconductor structure in accordance with some embodiments of the disclosure.
- a semiconductor structure of the present disclosure is illustrated below in detail. It should be noted that the following description provides many different embodiments, or examples, for implementing different aspects of some embodiments of the disclosure. Specific examples of components and arrangements described below are merely for describing some embodiments of the present disclosure briefly and clearly. These are, of course, merely examples and are not intended to be limiting. In addition, different embodiments may use like and/or corresponding numerals to denote like and/or corresponding elements in order to clearly describe the present disclosure. However, these like and/or corresponding numerals in different embodiments are merely used for clearly describing some embodiments of the present disclosure, and does not suggest any correlation between different embodiments.
- first and second components are formed in direct contact
- additional components may be formed between the first and second components, such that the first and second components may not be in direct contact
- present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.
- spatially relative terms such as “above,” “below,” “over,” “under,” and the like, encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures.
- the apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.
- the semiconductor structure forms a GaN-based high electron mobility transistor directly on a ceramic base.
- FIGS. 1 A- 1 E illustrate cross-sectional views of various stages of the forming process of a semiconductor structure.
- additional operations may be provided before, during, and/or after performing the process of forming a semiconductor structure 100 .
- some of the described stages may be replaced or eliminated.
- Additional features may be added to the semiconductor structure 100 .
- partial features of the semiconductor structure 100 described below may be replaced or eliminated.
- a ceramic base 102 is provided in the semiconductor structure 100 .
- the ceramic base 102 refers to ceramic materials other than silicon, such as silicon carbide, aluminum nitride (AlN) or aluminum oxide.
- the ceramic base 102 may be a polycrystalline material.
- the ceramic base 102 may be doped (for example, doped with a p-type or n-type dopant) or undoped.
- the ceramic base 102 is an amorphous or polycrystalline material.
- the ceramic base 102 includes a front surface and a back surface, wherein the front surface is the surface for forming devices. As shown in FIG.
- the front surface 102 a of the ceramic base 102 is a non-flat surface.
- there is a plurality of pits on the front surface 102 a wherein the sizes of the pits are usually between about 0.1 ⁇ m to 100 ⁇ m.
- a seed layer 104 is directly formed on the unpolished front surface of the ceramic base 102 , and the seed layer 104 is conformally formed on the non-flat front surface 102 a of the ceramic base 102 .
- the material of the seed layer 104 may include monocrystalline AlN, polycrystalline AlN, amorphous AlN, other suitable materials, or a combination thereof.
- the seed layer 104 may be formed by an epitaxial growth process.
- the seed layer 104 may be formed conformally on the front surface of the ceramic base 102 and in the plurality of pits of the front surface, for example, by atomic layer deposition (ALD), metal organic chemical vapor deposition (MOCVD), hydride vapor phase epitaxy (HVPE), molecular beam epitaxy (MBE), other suitable methods, or a combination thereof.
- ALD atomic layer deposition
- MOCVD metal organic chemical vapor deposition
- HVPE hydride vapor phase epitaxy
- MBE molecular beam epitaxy
- the seed layer 104 may also fills in the pits completely.
- a conductive layer (not shown) used for electrostatic chuck (E-chuck) may be formed on the back surface of the ceramic base 102 .
- the conductive layer may include, for example, doped polysilicon, or other conductive materials.
- the conductive layer may be formed by, for example, low pressure chemical vapor deposition (LPCVD).
- LPCVD low pressure chemical vapor deposition
- the conductive layer may also grow on the front surface and side surfaces of the ceramic base 102 .
- the conductive layer on the front surface of the ceramic base 102 may be removed by an etching process to prevent it from affecting the deposition of the seed layer 104 or other subsequent layers above the front surface of the ceramic base 102 .
- a nucleation layer 106 is formed on the seed layer 104 .
- the ceramic base 102 , the seed layer 104 , and the nucleation layer 106 may be collectively referred to as a semiconductor substrate 108 .
- the nucleation layer 106 may be used to mitigate the lattice difference between the seed layer 104 and the buffer layer described below.
- the nucleation layer 106 gradually transforms the crystalline phase from original amorphous or polycrystalline to polycrystalline or monocrystalline, thereby improving the crystalline quality. It is noted that the nucleation layer 106 may fills the pits which have not been completely filled, and have a substantially flat upper surface.
- a substantially flat upper surface means that the difference of thickness of the entire substrate is less than about 1 nm to 10 nm, such as about 2 nm to 5 nm.
- the nucleation layer 106 is a III-V compound of aluminum.
- the nucleation layer 106 may be formed with AlN, aluminum gallium nitride (Al x Ga 1-x N, 0 ⁇ x ⁇ 1), GaN, other suitable materials, or a combination thereof.
- the nucleation layer 106 may be deposited by metal organic chemical vapor deposition (MOCVD), hydride vapor phase epitaxy (HVPE), molecular beam epitaxy (MBE), other suitable methods, or a combination thereof.
- MOCVD metal organic chemical vapor deposition
- HVPE hydride vapor phase epitaxy
- MBE molecular beam epitaxy
- FIG. 1 D is a cross-sectional view of forming a compound semiconductor layer 110 on the nucleation layer.
- the compound semiconductor layer 110 is a GaN-based semiconductor layer.
- the compound semiconductor layer may include a buffer layer 112 disposed on the nucleation layer 106 , a channel layer 114 on the buffer layer 112 , and a barrier layer 116 on the channel layer 114 .
- the buffer layer 112 may mitigate the strain of the channel layer 114 , which is subsequently formed above the buffer layer 112 , to prevent defects from forming in the overlying channel layer 114 .
- the strain is caused by the mismatch between the structure of the channel layer 114 and the structure below the buffer layer 112 .
- the materials of the buffer layer 112 may include AlN, GaN, Al x Ga 1-x N (0 ⁇ x ⁇ 1), other suitable materials, or a combination thereof.
- the buffer layer 112 may be formed by an epitaxial deposition process, such as MOCVD process, HVPE process, MBE process, other suitable methods, or a combination thereof.
- the thickness of the formed buffer layer 112 may range from about 0.3 ⁇ m to about 30 ⁇ m, for example, about 5 ⁇ m, but the present disclosure is not limited to this. It should be understood that, although the buffer layer 112 in the embodiment illustrated in FIG. 1 D is a single-layer structure, the buffer layer 112 may also have a multilayer structure in other embodiments.
- two-dimensional electron gas (2DEG) may be formed between the heterojunction between the channel layer 114 and the barrier layer 116 .
- the semiconductor structure 100 (as shown in FIG. 1 E ) is a high electron mobility transistor (HEMT) using two-dimensional electron gas (2DEG) as conductive carriers.
- the channel layer 114 may be a GaN layer
- the barrier layer 116 formed on the channel layer 114 may be an Al x Ga 1-x N (0 ⁇ x ⁇ 1) layer, wherein the GaN layer and the Al x Ga 1-x N (0 ⁇ x ⁇ 1) layer may or may not contain dopants (for example, n-typed dopants or p-typed dopants).
- the channel layer 114 and the barrier layer 116 may be formed by an epitaxial growth process, such as, MOCVD process, HVPE process, MBE process, other suitable methods, or a combination thereof.
- the thickness of the formed channel layer 114 may be between about 5 nm and about 500 nm, for example, 400 nm, but the present disclosure is not limited to this. In some embodiments, the thickness of the formed barrier layer 116 may be between about 5 nm and about 30 nm, for example, about 15 nm, but the present disclosure is not limited to this.
- a cap layer 118 may be formed on the compound semiconductor layer.
- the cap layer 118 formed on the barrier layer 116 may be a III-V compound semiconductor material, used to passivate the surfaces of materials, to significantly suppress the current breakdown effect and reduce surface current leakage.
- the channel layer 114 , barrier layer 116 , and the cap layer 118 may all be formed by an epitaxial growth process, such as MOCVD, HVPE, MBE, combinations thereof or other similar methods.
- the thickness of the formed cap layer 118 may be in the range of about 0.5 nm to about 10 nm, such as about 2 nm, but the present disclosure is not limited to this.
- a gate G may be formed on the cap layer 118 , and a source S and a drain D may be formed on opposite sides of the gate G to form the semiconductor structure 100 .
- the materials of the gate G, source S, and the drain D may contain conductive materials, such as metal, metal silicide, other suitable conductive materials, or a combination thereof.
- the metals may include gold (Au), nickel (Ni), platinum (Pt), palladium (Pd), iridium (Ir), titanium (Ti), chromium (Cr), tungsten (W), aluminum (Al), copper (Cu), alloys thereof, other suitable materials, or a combination thereof.
- the gate G, source S, and the drain D may be formed on the cap layer 118 by chemical vapor deposition process, physical vapor deposition (PVD) process, evaporation process, sputtering process, other suitable processes, or a combination thereof. Then, the gate G, source S, and the drain D are formed through a patterning process. In some embodiments, the gate G, source S, and the drain D may be formed after the cap layer 118 is patterned. In this embodiment, the cap layer 118 is below the gate G only.
- PVD physical vapor deposition
- a semiconductor device with a high electron mobility transistor (HEMT) formed on a ceramic substrate which includes sequentially depositing a seed layer and a nucleation layer directly on an unpolished ceramic substrate, and a high electron mobility transistor device is formed above.
- a semiconductor substrate includes a ceramic base and multiple dielectric layers (such as aluminum nitride (AlN), tetraethoxysilane (TEOS), SiN, PEOX, etc.), multiple thermal junctions may be formed between the multiple dielectric layers, which is disadvantageous to high electron mobility transistor elements under high power operation.
- the semiconductor substrate of the present disclosure may not only prevent the formation of multiple thermal junctions, but may further shorten the fabrication time of the semiconductor substrate.
- GaN-on-Si may crack easily during the manufacturing process, which results in decreased overall yield, and increased cost. Therefore, the present disclosure may provide a semiconductor substrate with a ceramic base of 8 inches or more that does not crack, which is attractive to the industry.
- FIGS. 2 A- 2 F illustrate cross-sectional views of various stages of the forming process of a semiconductor structure in accordance with some alternative embodiments of the present disclosure.
- a dielectric filler is first deposited on a front surface of a ceramic substrate to fill in pits, and then epitaxial layers are deposited.
- similar elements will be represented by the same numerals of the elements.
- a ceramic base 102 is provided in a semiconductor structure 100 .
- the ceramic base 102 refers to a ceramic material other than silicon, such as silicon carbide, aluminum nitride or aluminum oxide.
- the ceramic base 102 doesn't comprise dielectric layer, such as silicon oxide, silicon nitride, silicon oxynitride, other suitable material or a combination thereof.
- the ceramic base 102 may be a polycrystalline material.
- the ceramic base 102 may be doped (for example, doped with p-typed or n-typed dopants) or undoped.
- the surface of the ceramic base 102 is an amorphous or polycrystalline material.
- the ceramic base 102 includes a front surface and a back surface, wherein the front surface is the surface for forming devices. As shown in FIG. 2 A , the front surface 102 a of the ceramic base 102 is a non-flat surface. In some embodiments, there is a plurality of pits P on the front surface 102 a .
- a conductive layer (not shown) used for electrostatic chuck may be formed on the back surface of the ceramic base 102 , wherein the materials and the forming method included may be similar to the aforementioned conductive layer.
- a dielectric filler 103 is formed on the front surface of the ceramic base 102 , and the dielectric filler 103 fills in the pits on the front surface of the ceramic base 102 .
- the materials of the dielectric filler 103 include borophosphosilicate glass (BPSG), borosilicate glass (BSG), phosphosilicate glass (PSG), tetraethoxysilane (TEOS) oxide, silicon oxide, silicon nitride, silicon oxynitride, low-k dielectric materials, other suitable materials, or a combination thereof.
- Low-k dielectric materials may include fluorinated silica glass (FSG), hydrogen silsesquioxane (HSQ), carbon doped silicon oxide, fluorinated carbon, parylene, bis-benzocyclobutenes (BCB) or polyimide.
- the dielectric filler 103 may be formed on the ceramic base 102 by spin coating process, chemical vapor deposition (CVD) process, atomic layer deposition (ALD) process, high density plasma CVD (HDPCVD) process, low pressure CVD (LPCVD), other suitable methods, or a combination thereof. As shown in FIG. 2 B , the dielectric filler 103 may completely fill in the pits P on the ceramic base 102 in some embodiments.
- a planarization process is performed on the dielectric filler 103 , such as chemical mechanical polishing (CMP), until the substrate exposes again to form a substantially flat front surface, as shown in FIG. 2 C .
- the front surface after the planarization process may include a remained dielectric filler 103 ′ and the ceramic base 102 , wherein the remained dielectric filler 203 ′ and the ceramic base 102 that exposes again are substantially coplanar.
- a seed layer 104 is formed on the front surface composed of the remained dielectric filler 103 ′ and the ceramic base 102 .
- the material of the seed layer 104 may include monocrystalline AlN, polycrystalline AlN, amorphous AlN, other suitable materials, or a combination thereof.
- the seed layer 104 may be formed by an epitaxial deposition process, for example, the seed layer 104 having a substantially flat upper surface may be formed by atomic layer deposition (ALD), metal organic chemical vapor deposition (MOCVD) process, hydride vapor phase epitaxy (HVPE) process, molecular beam epitaxy (MBE) process, other suitable methods, or a combination thereof.
- ALD atomic layer deposition
- MOCVD metal organic chemical vapor deposition
- HVPE hydride vapor phase epitaxy
- MBE molecular beam epitaxy
- FIG. 2 E is a cross-sectional view of forming a nucleation layer 106 on the seed layer 104 in accordance with some embodiments of the present disclosure.
- the ceramic base 102 , the remained dielectric filler 103 ′, the seed layer 104 , and the nucleation layer 106 may be collectively referred to as a semiconductor substrate 108 .
- a compound semiconductor layer 110 is formed on the nucleation layer, wherein the compound semiconductor layer may include the buffer layer 112 disposed on the nucleation layer 106 , the channel layer 114 on the buffer layer 112 , and the barrier layer 116 on the channel layer 114 .
- a cap layer 118 may be formed on the compound semiconductor layer.
- the materials and the forming methods of the respective layers of the compound semiconductor layer 110 and the cap layer 118 are the same as or similar to embodiments where the dielectric filler 103 ′ is not included in the semiconductor structure 100 .
- a gate G may be formed on the cap layer 118 , and a source S and a drain D may be formed on opposite sides of the gate G to form a semiconductor structure 100 .
- the materials and the forming methods included in the gate G, source S, and the drain D are the same as or similar to the embodiments where the dielectric filler 103 ′ is not included in the semiconductor structure 100 .
- this embodiment also forms a semiconductor device with a high electron mobility transistor (HEMT) formed on a ceramic substrate, which includes sequentially depositing a dielectric filler, a seed layer, and a nucleation layer as filling materials on the ceramic substrate, and a HEMT device is formed above.
- HEMT high electron mobility transistor
- this embodiment may also shorten the fabrication time of the substrate to, such as 2 days.
- large-sized pits e.g. pits larger than 10 ⁇ m may be filled more effectively.
- the present disclosure provides a semiconductor structure.
- a high electron mobility transistor HEMT
- a semiconductor structure may be provided by first depositing a dielectric filler to fill in pits on the ceramic base, followed by depositing a seed layer.
- a GaN-based HEMT may be formed directly on the ceramic substrate.
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| US9620362B2 (en) * | 2015-04-29 | 2017-04-11 | Taiwan Semiconductor Manufacutring Co., Ltd. | Seed layer structure for growth of III-V materials on silicon |
| US10453947B1 (en) * | 2018-06-12 | 2019-10-22 | Vanguard International Semiconductor Corporation | Semiconductor structure and high electron mobility transistor with a substrate having a pit, and methods for fabricating semiconductor structure |
| US20190371929A1 (en) * | 2017-01-18 | 2019-12-05 | QROMIS, Inc. | Gallium nitride epitaxial structures for power devices |
| US20210273084A1 (en) * | 2020-03-02 | 2021-09-02 | Taiwan Semiconductor Manufacturing Co., Ltd. | Rough buffer layer for group iii-v devices on silicon |
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2020
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9620362B2 (en) * | 2015-04-29 | 2017-04-11 | Taiwan Semiconductor Manufacutring Co., Ltd. | Seed layer structure for growth of III-V materials on silicon |
| US20190371929A1 (en) * | 2017-01-18 | 2019-12-05 | QROMIS, Inc. | Gallium nitride epitaxial structures for power devices |
| US10453947B1 (en) * | 2018-06-12 | 2019-10-22 | Vanguard International Semiconductor Corporation | Semiconductor structure and high electron mobility transistor with a substrate having a pit, and methods for fabricating semiconductor structure |
| US20210273084A1 (en) * | 2020-03-02 | 2021-09-02 | Taiwan Semiconductor Manufacturing Co., Ltd. | Rough buffer layer for group iii-v devices on silicon |
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